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At least 379 records · Page 21

A comparison of surrogate constitutive models for viscoplastic creep simulation of HT-9 steel

Mechanistic microstructure-informed constitutive models for the mechanical response of polycrystals are a cornerstone of computational materials science. However, as these models become increasingly more complex – often involving coupled differential equations describing the effect of specific deformation modes – their associated computational costs can become prohibitive, particularly in optimization or uncertainty quantification tasks that require numerous model evaluations. To address this challenge, surrogate constitutive models that balance accuracy and computational efficiency are highly desirable. Data-driven surrogate models, that learn the constitutive relation directly from data, have emerged as a promising solution. In this work, we develop two local surrogate models for the viscoplastic response of a steel: a piecewise response surface method and a mixture of experts model. These surrogates are designed to adapt to complex material behavior, which may vary with material parameters or operating conditions. The surrogate constitutive models are applied to creep simulations of HT-9 steel, an alloy of considerable interest to the nuclear energy sector due to its high tolerance to radiation damage, using training data generated from viscoplastic self-consistent (VPSC) simulations. In conclusion, we define a set of test metrics to numerically assess the accuracy of our surrogate models for predicting viscoplastic material behavior, and show that the mixture of experts model outperforms the piecewise response surface method in terms of accuracy.

36 MATERIALS SCIENCE↗

Electrochemical study of the dissolution of oxide films grown on type 316L stainless steel in molten fluoride salt

The corrosion behavior of oxide films grown on Type 316L stainless steel (SS) in molten FLiNaK (LiF-NaF-KF: 46.5−11.5−42 mol.%) salt was investigated. The results show that the oxide film formed on Type 316L SS is unstable and can only temporarily protect materials from corrosion in molten FLiNaK salt. Based on the electrochemical impedance spectroscopy, the oxide dissolution rate is calculated to be 0.85 nm/h at 700 °C in molten FLiNaK salt. Finally, after the oxide film dissolved, Cr and Fe are selective dealloyed from the steel, leading to intergranular corrosion of Type 316L SS in molten fluoride salt.

EIS↗

Enhanced crevice corrosion of stainless steel 316 by degradation of Cr-containing hollandite crevice former

This study explores the corrosion interactions between stainless steel 316 (SS316), a candidate nuclear waste canister material, and Cr-containing hollandite (Ba 1.15 Cr 2.3 Ti 5.7 O 16 ), a model ceramic nuclear waste form. The two materials were corroded in close proximity in 0.6 M NaCl solution at 90 °C for 28 days. Severe crevice corrosion was observed on the stainless steel surface after the corrosion experiment, which is likely associated with the rapid accumulation of Cr 3+ cations originating from both SS316 and the Cr-containing hollandite. Furthermore, the enhanced corrosion of SS316 by the corrosion products of hollandite is quantitatively explained using a classical crevice corrosion model.

36 MATERIALS SCIENCE↗

Reverse martensitic transformation on the corrosion behavior of a 2304 lean duplex stainless steel

This study investigates the influence of the reverse martensitic transformation on the corrosion behavior of 2304 lean duplex stainless steel (LDSS) at low temperatures (400–600°C). The steel underwent cold rolling, followed by isochronal annealing for 0.5 h. Phase transformations and microstructures were analyzed using X-ray diffraction, scanning electron microscopy, and transmission electron microscopy. Corrosion resistance was evaluated using a syringe cell with cyclic potentiodynamic polarization in 0.6 M NaCl solution and double-loop electrochemical potentiokinetic reactivation in 0.5 M H 2 SO 4 + 0.001 M KSCN solution. A bimodal breakdown potential behavior, associated with either pitting or transpassivity, was observed in the as-received (AR) and samples annealed at 400°C. Pitting in the AR sample was associated with Al–Mg–Si–Ca–O inclusions, while pitting on the samples annealed at 400°C was linked to local reduced passive film resistance. Severe cold rolling enhanced the pitting resistance of 2304 LDSS. Selective electrochemical etching revealed preferential corrosion at phase interfaces and within the austenite phase. Additionally, annealing at 500°C to 600°C led to a marked decrease in pitting resistance and increased sensitization. Electron backscatter diffraction analysis of the corroded pits in the annealed specimens indicated that pits tend to nucleate and grow in α'-martensite/austenite regions. Furthermore, the nanostructure formed during low-temperature reversion, characterized by dislocation-cell martensite with high dislocation density and stacking faults, may adversely affect corrosion resistance due to heterogeneities associated with alloying element redistribution.

36 MATERIALS SCIENCE↗

Oxidation of porous stainless steel supports for metal-supported solid oxide electrolysis cells

Oxidation behavior of porous P434L ferritic stainless steel, used for the fabrication of metal-supported solid oxide electrolysis cells (MS-SOEC), is studied under oxygen-side and steam-side conditions. The impact of oxygen content on the oxygen side and steam:hydrogen ratio on the steam side is determined at 700°C for bare, as-sintered samples. For these conditions, oxidation is more aggressive in the steam-side atmosphere. Oxygen with 3% humidification and steam:hydrogen ratio of 90:10 are selected for further assessment with pre-oxidized, catalyst-coated, and CuMn1·8O4-coated samples. The rapid oxidation at 700°C and breakaway oxidation at 600 °C observed for bare stainless steel in 90:10 steam:hydrogen is mitigated by pre-oxidizing the sample in air before exposure. In oxygen, addition of the catalyst or CuMn 1·8 O 4 coatings moderately increases the oxidation rate, due to consumption of Cr via reaction between the coatings and Cr-oxide scale. In conclusion, the results for ex-situ controlled oxidation are similar to oxidation observed after 1000h operation of a full MS-SOEC. In general, the oxidation behavior at 700°C is found to be acceptable.

08 HYDROGEN↗

Effects of hydrogen partial pressure on crack initiation and growth rate in vintage X52 steel

There is an increasing interest in ensuring compatibility of existing natural gas infrastructure with conveyance of hydrogen, especially for vintage (pre-1970s) pipeline steels. While hydrogen is known to affect the fatigue and fracture resistance of these materials, there is a lack of data on its effects on crack initiation at low hydrogen partial pressure. To address this gap, the current work presents a series of fatigue tests on vintage API Grade X52 steel in pure nitrogen, air and gaseous hydrogen at partial pressures of 1 and 207 bar. Circumferential notch tension (CNT) specimens with direct current potential difference (DCPD) measurements are used to get S–N curves for crack initiation and failure, and compact tension (CT) tests to assess crack growth rates. Results indicate that air accelerates crack initiation, low hydrogen partial pressure affects the crack growth rate, and higher pressures have the largest impact on both. Surprisingly, crack initiation is faster in air than at 1 bar hydrogen partial pressure. The CNT tests also reveal that the orientation of the banded microstructure has no effect on the crack initiation site, but it influences its growth behavior. Moreover, fractography shows that hydrogen also promotes instances of quasi-cleavage and intergranular fracture, linked to embrittlement of the material. Here, these results demonstrate that, while hydrogen may impact the entirety of the fatigue process, its effects on the early stages of damage accumulation become relevant only at larger pressures. More comprehensive studies of crack initiation in hydrogen atmospheres will be critical to future codes and standards for hydrogen infrastructure.

Circumferential notch tension↗

Predicting the creep-rupture lifetime of a cast austenitic stainless steel using Larson-Miller and Wilshire parametric approaches

An experimental dataset of just over 100 creep tests of a cast austenitic stainless steel, CF8C-Plus, was analyzed by two temperature-compensated parametric models (Larson-Miller, Wilshire et al.) to predict long-term lifetimes as functions of temperature and stress. The dataset and associated regression analyses showed greater scatter than typically found in recent similar studies of wrought Ni-based alloys by the same two models and was attributed to the microstructural inhomogeneity of the cast stainless steel. Qualitatively, the Larson-Miller formalism showed greater lifetime prediction accuracy than the Wilshire approach, with the latter model's predictive ability being particularly degraded by the presence of two very significant outlier results. This observation suggests that the Larson-Miller approach is more robust when treating rupture-time datasets that show particularly wide experimental scatter. Despite the differences in the overall predictive ability, both models yielded similar predictions of the applied stress at which CF8C-Plus would have a creep-limited lifetime of 100,000 h when loaded below the yield point.

36 MATERIALS SCIENCE↗

Achieving clean production with nanostructured coated milling tools dry machining low carbon steel

The advancement of clean production using nanostructured materials in subtractive manufacturing processes has focused on replacing the use of liquid lubrication with solid lubricants coated to conventional cutting tools machining low carbon steel (~ 0.2 wt. % carbon). However, little is known about the wear mechanisms that dominate such tools when coated with functional graded nanostructured coatings. The present study follows an international standard for characterizing such wear (ISO 8688) but uses advanced measurement techniques such as x-ray fluorescence technology to measure the diffusion of chemical species from tool to workpiece and vice versa, that contributes to tool wear with the view to enhance the principles of cleaner production. The results show that when commercially-available tools coated with the appropriate functionally graded industrial coating, diffusion does not take place and creates an effective chemical barrier during machining. The experimental methods used in the study include machining workpieces using a CNC milling machine, tachometer for measuring spindle speed, dynamometer for measuring cutting forces, infra-red camera for measuring cutting temperatures, chemical species diffusion wear using x-ray florescence detector, and an optical microscope for measuring tool wear. Coupled with the physical measurement of wear, it is concluded that mechanical wear dominates the milling of a low carbon steel and that thermal properties of the coatings do not correlate with such wear. It is also concluded that flank wear as a function of volume of workpiece removed and machining duration (machining index) is a sound method for assessing the transition of the stages of wear during clean machining operations. The present study not only has implication for the design of better cutting tools, but also advances dry machining processes that eliminate the use of liquid lubricants making subtractive production processes cleaner. The main conclusions drawn from this study show that coated tools have a longer life under dry conditions compared to uncoated tools and that there is no correlation between coating properties and tool wear. In conclusion, diffusion of chemical species into the cut chips did not occur because of the lack of thermally induced chemical wear of the cutting tool and that wear is caused by the gradual erosion of the flank face due to the chip abrading the cutting tool.

36 MATERIALS SCIENCE↗

Biaxial steel plated concrete constitutive models for composite structures: Implementation and validation

The Steel-plated Concrete (SC) technique is an alternative construction technique with faster onsite construction speed, reduced construction time, and increased structural performance. Aiming to predict the force transfer mechanism of SC elements, an innovative constitutive model package is proposed by implementing experimental-based biaxial steel plate concrete models into the nonlinear finite element (FE) model “Membrane Model of SC (MM-CS).” First, the formulation and implementation of the MM-SC is illustrated in detail, including the equilibrium and compatibility equations and the implementation of constitutive models. Next, various experimental data of SC members are selected and simulated using the proposed MM-SC model. In this research, two types of structures, SC panels and framed SC shear walls, and three types of loading conditions, including uniaxial compression, pure shear, and combined axial-flexural-shear tests, are analyzed respectively. Good agreements were obtained between the reported results and the FE simulation results in terms of yield capacity and ultimate capacity, proving the reliability of the implemented analytical constitutive material models and the biaxial membrane model formulations.

42 ENGINEERING↗

Leak-tight crack repair for 304L stainless steel using friction surfacing

Here, friction surfacing (FS) was investigated as a method for sealing 50 μm wide thru-cracks in 3-mm-thick 304L stainless steel (304L) plate. Friction surfacing was performed using two sizes of 304L consumable rod, with diameters of 9.52 mm and 12.7 mm, on two substrate conditions (clean and oxidized). Friction surfacing was able to deposit a 600 μm thick coating and repair cracks to a depth of 100 μm - 200 μm below the original surface, when using the 12.7-mm-diameter consumable rod for both substrate conditions. Helium leak rates of 10 -10 atm-cc/s were achieved on crack repairs, designating them as leak-tight by the ANSI N14.5 standard. Optical and scanning electron microscopy were used to investigate the coating microstructure and bond interfaces. In this study, the 12.7-mm-diameter rod performed better with disruption of the oxide layer on the oxidized substrate and providing a more homogenous coating. Mechanical properties of the coated samples were evaluated by performing micro-indentation, tensile, bending, and adhesion testing. Higher hardness in the coatings was observed due to the fine equiaxed grains resulting from dynamic recrystallization. Complete consolidation of plastically deformed material on the substrate and a strong diffusion bond across the interface was observed. This was reflected in tensile and bending properties of the FS coatings being comparable to those of uncoated specimen. No delamination of the FS coating was observed during adhesion testing. The results demonstrate that friction surfacing is a viable option to seal cracks in stainless steels.

36 MATERIALS SCIENCE↗

Effect of nitriding on mechanical and microstructural properties of Direct Metal Laser Sintered 17-4PH stainless steel

In this work, the effect of the nitriding process on microstructure and mechanical properties of additively manufactured (AM) 17-4PH stainless steel is investigated. The nitriding was performed at 530 °C, 560 °C, and 580 °C for 2 h. The nitriding process improves the hardness and surface roughness of the AM 17-4PH steel. Detailed microstructural characterizations of both as-built and nitride samples are performed using an optical microscope, scanning electron microscope (SEM) equipped with energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction technique. It reveals that the nitride layer thickness increases with nitriding temperature. A distinct transition layer between the substrate and nitride layer is observed in the 560 °C and 580 °C nitride samples. The nitriding process develops almost equiaxed grain microstructure with new secondary phase precipitates, whereas in the as-built material, the grains are primarily columnar along the AM process build direction. Specifically, the nitriding process introduces γ-Fe4N, ε-Fe3N, CrN, and Ni3N precipitates. The increase in Ni- and Cu-rich precipitates with the nitriding temperature explains the observed improvement in the hardness and surface roughness. Furthermore, the nitriding process does not alter the substrate's initial weak crystallographic texture.

17-4PH steel↗

Characterisation of nano-scale precipitates in BOR60 irradiated T91 steel using atom probe tomography

Atom probe tomography has characterised the microstructural changes in T91 steel after BOR60 reactor irradiation at five temperatures between 376 °C and 524 °C to doses between 14.6 dpa and 35.1 dpa. Irradiation-induced precipitation and segregation to carbide/matrix interface induced by neutron irradiation has been characterised. Atom probe tomography characterisation shows that Mn, Ni, Si -rich (MNS-rich) clusters form in T91 steel irradiated in BOR60 reactor at temperatures between 376 °C and 415 °C, which is not observed at higher temperatures 460 °C and 524 °C. Additionally, the number density, volume fraction and composition of MNS-rich clusters have been characterised. Ni, Mn, Si and P is found to segregate at carbide matrix interface after irradiation at lower temperature and only P segregation is observed at 524 °C.

36 MATERIALS SCIENCE↗

An Atom Probe Tomography Study of the Through Wall Attenuation Effect on Cu-rich Precipitate Formation in a Reactor Pressure Vessel Steel

In this study, high-Cu weld material harvested from an ex service reactor pressure vessel (RPV) steel from Unit 1 of the decommissioned Zion Nuclear Generating Station has been characterized using atom probe tomography. Samples taken from 4 different positions through the thicknesses of the pressure vessel wall from the water-side to the air-side were characterized, along with an unirradiated baseline material. In the baseline material, no precipitates were found and the Cu was observed to be fully in solid solution; however, scanning transmission electron microscopy combined with energy dispersive spectroscopy (STEM-EDS) revealed the presence of ϵ -Cu that form during processing of the material and results in the concomitant decrease of matrix Cu. Following irradiation, a high number density of nano-scale Cu-rich precipitates (CRPs) were observed, uniformly distributed throughout the matrix. The Cu content within the CRPs was found to be ~30-35 at.% regardless of location in the wall. No statistically significant variation in the compositions, mean radius, number density, or volume fraction as a function of location within the wall was observed. The measured matrix Cu level excluding CRPs contribution was found to be ~90 appm higher than the solubility limit suggesting that further nucleation and growth of the CRPs under continued operations would have occurred. These results clearly demonstrate that the neutron energy attenuation has no significant effect on the precipitation kinetics of CRPs regardless of location in the wall in high-Cu RPV steels under irradiation.

36 MATERIALS SCIENCE↗

Creep behavior of 316 L stainless steel manufactured by laser powder bed fusion

Additive manufacturing as a new processing technique can produce unique microstructure that is difficult to achieve using conventional techniques. Here, we have investigated the creep behavior of 316 L stainless steel produced by a laser powder bed fusion process at temperatures of 550, 600 and 650 °C and stresses between 175 and 300 MPa. We found that additively-manufactured 316 L stainless steel had a higher stress dependence of the minimum creep rate than conventionally-made Type 316 SS, which could be attributed to the dislocation cell structure resulting from the printing process. The dislocation cell structure was unstable under creep, evolving into a uniform dislocation structure under the test conditions. While internal porosity in AM 316 L SS may serve as nucleation sites of creep voids and may be responsible for a relatively lower creep life, additively-manufactured 316 SS did not show inferior creep ductility when compared with conventionally-made 316 SS. The creep life of AM 316 L SS could be improved by stabilizing dislocation cell structure and/or reducing internal porosity through an optimized additive manufacturing process.

316 L stainless steel↗

Microstructure analysis of laser beam weldments performed on neutron-irradiated 304L steel containing 3 and 8 appm helium

We report that AISI 304 L austenitic stainless steel is one of the major structural materials used in light water reactors (LWRs). In the future, 304 L components may require repair, and several welding techniques have been proposed as candidates. In this study, laser beam welding using the low-energy contribution approach was performed in ~2016 on neutron-irradiated AISI 304 L steel with nominal values of 3 and 8 appm helium (He). The goal was to investigate the impact of helium on the irradiated material weldability and evaluate helium-associated damage. The weld and heat-affected zone (HAZ) microstructure was studied using scanning electron microscopy, electron backscatter diffraction, and transmission electron microscopy (TEM). Analysis of the weldment cross-sections did not reveal severe cracking. Still, evidence of incipient helium-associated damage was observed in the HAZ, manifesting as degraded grain boundaries (GBs) “decorated” by pore chains and mostly small (i.e., ≤ 25-30 µm) scattered cracks. The largest observed crack was ~50 µm in length. Helium-associated damage was localized within ~200-300 µm of the weld pool boundary, and the fraction of the compromised GBs, as a rule, was below ~9-11% of the total GB network. TEM analysis showed significant annealing of the radiation-induced defects at distances up to ~300 µm from the weld pool boundary. Inside the HAZ, the cavities (likely, helium bubbles) tended to form at GBs and inclusions, such as manganese sulfide precipitates in the grain interior. Crystallography analysis of the HAZ damage showed that random high-angle boundaries were most susceptible to helium-associated damage. In contrast, low-angle random boundaries and twin boundaries appeared to be strongly resistant to degradation from the combined effects of helium and welding.

36 MATERIALS SCIENCE↗

A fusion relevant data-driven engineering void swelling model for 9Cr tempered martensitic steels

The UCSB database on cavity evolution in 9-12Cr tempered martensitic steels (TMS), includes the results for both dual heavy and helium ion (DII), and High Flux Isotope Reactor (HFIR) in situ helium injection (ISHI) neutron irradiations at 500°C. These results were combined with literature single ion and fission neutron irradiation data to derive a model for the void volume fraction, f v , as a function of displacements per atom (dpa) and transmutant helium concentrations in atomic parts per million (appm). The scientific foundation for the paper is described in a companion paper entitled “Cavity Evolution and Void Swelling in Dual Ion Irradiated Tempered Martensitic Steels”. Here, in this study, we show that f v (dpa, He/dpa) is described by the incubation dose, dpa i , for the onset of void growth, and the post-incubation growth rate, f v ’(%/dpa). Both dpa i and f v ’ decrease with increasing He/dpa at > ~ 5. The dpa i is also lower for the ISHI neutron irradiations at the same He/dpa. Single heavy ion and fission reactor neutron irradiations, with low He/dpa ratios, have a much larger dpa i . Based on a combined analysis of DII, single ion, ISHI and fission neutron data, we further show that the post-incubation f v data analyzed here have a common empirical curve shape, with f v ’ reaching up to ~ 0.2%/dpa at very high dpa. We also show that f v ’ can be predicted based on a physical model of defect partitioning between evolving sinks. At 500°C and fusion relevant He/dpa ≈ 10, the best-fit model predicts nominal swelling, S = f v /(1-f v ), of ~ 1.1, 4.9 and 16% at 50, 100 and 200 dpa, respectively. The physically motivated, data-driven model includes estimated uncertainties for both dpa i and f v ’.

36 MATERIALS SCIENCE↗

Weldability of irradiated Stainless Steel 304 materials harvested from the National Research Universal (NRU) reactor

In this work, the weldability of the neutron-irradiated Stainless Steel 304 (SS 304) materials containing estimated helium levels of 12 to 44 appm has been studied through a Collaborative Research and Development Agreement between the Canadian Nuclear Laboratories and Oak Ridge National Laboratory. The work utilizes a SS 304 component harvested from the National Research Universal reactor. Laser beam welding was used to explore suitable welding conditions and associated parameters, to determine helium concentration limits for successful welding of irradiated stainless-steels. The experimental results show that maximum fusion zone void sizes, fusion zone void quantity and total heat affected zone helium-induced crack length generally increased with increasing He levels and effective weld heat input. A proper combination of welding parameters with low effective heat input, such as, laser power, weld travel speed and wire feed speed, were shown to improve the welding quality, and potentially reduce the length and probability of the formation of grain boundary helium-induced cracking and voids of irradiated SS 304 even with He concentrations as high as about 44 appm.

36 MATERIALS SCIENCE↗

Dynamic data-driven multiscale modeling for predicting the degradation of a 316L stainless steel nuclear cladding material

Here, we have developed a long short-term memory stacked ensemble (LSTM-SE) surrogate modeling approach that can provide rapid predictions of microstructural evolution and the resultant mechanical properties of American Iron and Steel Institute (AISI) 316L series stainless steel (316LSS) fuel cladding under conditions of varying temperature and radiation dose rate. To acquire training data, we developed and implemented a kinetic Monte Carlo (KMC) model to simulate precipitation kinetics of M 23 C 6 , γ', and G phases within SS316L cladding. Experimentally reported precipitation kinetics of SS316L in literature were linked to the kinetic parameters of the simulated precipitation in our KMC model. The model was then used to simulate microstructure evolution under synthetically generated treatments of varying temperature and radiation dose rate, for periods of up to 3000 hours. Changes in volume fraction, number density, and particle size of precipitates were recorded, and particle area fractions were correlated using statistical methods to develop the surrogate model. Simultaneously, the mechanical properties of the simulated microstructures were evaluated using microstructure-based finite element method (FEM) analysis to determine the elastic modulus, yield stress, ultimate tensile strength, and elongation to failure of the aged microstructures. Using this approach, our surrogate model can predict precipitation behavior within 0.25% volume fraction and mechanical properties within 6% relative error from the values predicted by the KMC and FEM models using 50 training simulations as input. The trained recurrent neural network-based model can return estimations of precipitation kinetics and mechanical properties ~1000 times faster than the physics-based codes. This work demonstrates, as a proof of concept, that reactor material service lifetimes under variable service conditions can be predicted for a statistics-based model from a practicably obtainable dataset.

36 MATERIALS SCIENCE↗